Furniture construction with elastic or spring modules

ABSTRACT

Furniture is assembled from elastic modules enabling rapid and convenient assembly and disassembly. The elastic module has a spring, an outer covering layer, and an end member attached to an end face of the outer covering layer. A mattress includes a plurality of individual spring assemblies ( 145 ), with each spring assembly including at least one spring ( 134 ) and a spring cap ( 144, 150, 161, 164, 171, 184, 194, 204 ). Each spring cap has at least one first attachment fitting ( 168, 178, 174, 186, 196 ) and at least one second attachment fitting ( 169, 180, 176, 187 ) with each first attachment fitting engageable into or onto and removable from a second attachment fitting of an adjoining spring cap. The spring assemblies are attached to each other via the first and second attachment fittings, forming the individual spring assemblies into a spring core. A top pad is positioned on top of the spring core. The mattress can be quickly dis-assembled and stored in a compact space by removing the top pad and separating the spring assemblies from each other.

FIELD OF THE INVENTION

The field of the invention is furniture and mattresses and modules whichcan be assembled into a furniture pad or mattress.

BACKGROUND OF THE INVENTION

With urbanization, population movement is accelerated and more frequent.In the house-moving process, disassembling and moving large furniture,like a couch, bed, etc., is difficult. At times, large and still useablefurniture is discarded to ease the burden of the move. Accordingly,designing furniture so that it can be easily disassembled and/orassembled (e.g. with or without using tools), may greatly reduce theenergy, time and economic costs consumed in the moving process.

A couch or bed typically consists of a frame (a bed frame or couchframe), a spring pad (couch cushion or bed mattress) and an outer cover(a cloth or leather cover, etc.). Most spring pads have a traditionalform in which a plurality of overlaid layers and springs are formed intoan integral pad. The integral pad conventionally includes a plurality ofelastic elements (e.g. springs) substantially arranged in a plane andvarious sponge or rubber mass layers integrally covering the outer sidesof the springs to provide a comfortable support. Generally the springpad is an un-detachable integral structure.

A so-called “independently bagged spring” bed mattress is intended toprevent two or more persons simultaneously lying on a bed frominfluencing one another (e.g. if the weight difference betweenindividuals is relatively great, one person inevitably influences theother(s) when turning over or moving his/her body). In this type ofmattress, each spring is separately packaged in a bag or sleeve made ofnon-woven fabrics or other materials. The spring bags are arranged in apattern and afterwards the outside of the arranged spring bag group iscovered by an integral piece of foam rubber by adhesion, binding, etc.,to produce the desired spring pad in the form of a furniture pad ormattress. However, the finished spring pad is still an integral product.Since the individually packaged spring bags are not separable orremovable from the mattress, the mattress is still overly large, makingit difficult to move or store.

Accordingly, there is a need for improved furniture designs, and fordesigns which can be more easily disassembled, moved and re-assembled,and also more easily stored.

BRIEF STATEMENT OF THE INVENTION

In one aspect, an elastic or spring module includes at least one spring,and an outer covering layer formed of a foam or sponge type materialsurrounding the spring. The elastic module may also have an end memberon a bottom or end face of the outer covering layer. The end member, ifused, includes a module connecting structure for attaching the elasticmodule to another optionally identical elastic module. The end membermay also include a frame connecting element for attaching the elasticmodule to a support frame, such as a bed frame or a couch frame. Themodule connecting structure, and the frame connecting element, if used,can be manually attached and detached preferably without using tools.The module connecting structure and the frame connecting element mayoptionally be attached to the outer covering layer if desired, or if noend member is used.

In the elastic module the springs and an outer covering layer (e.g. anouter foam rubber or similar covering layer of e.g., polyurethane)provide a comfortable support for a user. A spring pad or mattress madeup of elastic modules may be quickly assembled or dis-assembled. Thus,furniture which can be much more easily moved and stored is provided.

An outer end face of the elastic module may have an ergonomic curvature,such that a plurality of elastic modules, when assembled as for exampleinto a couch, can have a configuration conforming to the back of thehuman body.

The module connecting structure, which may be on the end member, in oneform includes a recess in a sidewall of a plate of the end member of afirst elastic module, and a protrusion on a sidewall of a plate of themodule connecting structure of an adjoining second elastic module, withthe protrusion configured to engage into the recess. As another example,the module connecting structure includes a recess on the outward surfaceof the end member of a first elastic module, and a protrusion on theoutward surface of the end member of an adjoining second elastic module,with the protrusion configured to have a shape complementary to therecess. By snapping the recess of the end member of one elastic moduleinto engagement with a complementary protrusion of the end member onanother elastic module, the two elastic modules may be horizontally orvertically mounted. Alternatively, the module connecting structure mayhave a mounting hole formed on a body or plate of the end member, withthe hole receiving a separate locking piece such that a plurality of theelastic modules can be detachably coupled together. The end member maybe metal, plastic or a sponge material.

In another aspect, the spring may be a spiral spring, specifically acylinder spiral spring, conical spiral spring, middle-portion-convex orconcave spiral spring, or a spiral spring formed by nesting aleft-handed spring and a right-handed spring. The outer covering layerand the spring can be integrally foam-molded within a mold. That is, thespring may be a metal spring, or the spring may be non-metal plastic ormolded material. At least one spring may be nested on a core located inthe middle of the mold before molding. The outer covering layer may befoam-molded independently of the spring, with the middle portion removedfor arranging the spring. The outer covering layer may partiallysurround the spring. With the spring molded together with the outercovering layer, the spring and the outer covering layer are provided asintegral unit, with the spring made of the molding material.

In a separate aspect a mattress includes a plurality of individualspring assemblies, with each spring assembly including at least oneconical spring and a spring cap. Each spring cap has at least one firstattachment fitting and at least one second attachment fitting with eachfirst attachment fitting engageable into or onto, and removable from, asecond attachment fitting of an adjoining spring cap. The springassemblies may be identical to each other. The spring assemblies areattached to each other via the first and second attachment fittings,forming the individual spring assemblies into a spring core. A top padis positioned on top of the spring core. Side pads may be positionedaround a perimeter of the top pad and/or the spring core. The mattresscan be quickly and easily assembled and dis-assembled, without tools,and stored in a compact space by removing the top pad and separating thespring assemblies from each other. The springs and spring caps can thenbe formed in nested stacked columns, with the column of springscontained inside of the column of spring caps. Spring clips may be usedinstead of spring caps.

In another aspect, a mattress includes a flat webbing and a plurality ofspring caps attachable to the flat webbing. A plurality of springs areprovided with each spring attachable to a spring cap. A top pad ispositioned on top of the springs. The flat webbing may be flexible toallow the webbing to be rolled up into a tube or folded up, and the flatwebbing may be perforated or have a grid pattern of through openings.

Elements described in one embodiment may of course be used separately orin combination in other embodiments.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings, the dimensions do not necessarily represent actualdimensions or scale of the designs. The drawings are only illustrative,and certain non-essential elements may be omitted for clarity.

FIG. 1a -FIG. 1b are respectively a perspective view and a sectionalview of an elastic module.

FIG. 2 is a perspective view of an elastic module provided with an endmember in another embodiment.

FIG. 3 is a perspective view of two elastic modules of FIG. 2transversely assembled together.

FIG. 4a -FIG. 4c are respectively sectional views of elastic modulesassembled with three different types of springs.

FIG. 5a -FIG. 5b are respectively a front view and a top view of theassembled elastic modules as shown in FIG. 2.

FIG. 6 is a top view of transversely assembled elastic modules.

FIG. 7a -FIG. 7d illustrate an example of a module connecting structureconnecting elastic modules.

FIG. 8a -FIG. 8 b; FIG. 9a -FIG. 9 c; FIG. 10a -FIG. 10 d; FIG. 11a-FIG. 11 b; FIG. 12a -FIG. 12 b; and FIG. 13a -FIG. 13b are schematicviews of embodiments of an elastic module.

FIG. 14 schematically illustrates a state in which elastic modules aremounted in a storage device independently from one another.

FIG. 15a -FIG. 15d are schematic views of an exemplary bed mattressformed of elastic modules.

FIG. 16a -FIG. 16b are schematic views of an exemplary couch formed ofelastic modules.

FIG. 17 schematically illustrates a folded state of a spring padassembled from elastic modules.

FIG. 18 schematically illustrates an exemplary couch made by mountingelastic modules onto a support frame.

FIG. 19 is an exploded view of elastic modules, which schematicallyillustrates a frame connecting element for attaching elastic modules toa furniture frame.

FIG. 20a -FIG. 20c schematically illustrate a spring pad formed ofelastic modules.

FIG. 21a -FIG. 21d schematically illustrate a spring pad formed ofelastic modules.

FIG. 22A is a perspective and cutaway view of a spring mattress.

FIG. 22B is a top perspective view of a bottom sheet of the springsprings on.

FIG. 23 is a section view of the mattress shown in FIG. 22.

FIG. 24A is an inverted perspective view of one of the spring assembliesshown in FIGS. 1 and 2.

FIG. 24B is a perspective view of another spring assembly.

FIG. 25 is a perspective view of part of the spring core shown in FIGS.22 and 23.

FIG. 26 is a top view of part of another spring core.

FIG. 27A is a perspective view of part of a spring core having a gridwebbing or backing plate.

FIG. 27B is a perspective view of part of a spring core having a solidor continuous webbing or backing plate.

FIG. 27C is a perspective view of part of a spring core having analternative webbing or backing plate.

FIG. 27D is a perspective view of the springs without spring caps in astacked form.

FIG. 27E is a perspective view of part of a spring core having analternative webbing or backing plate, similar to the embodiment shown inFIG. 27C.

FIG. 27F is a perspective view of the alternative webbing or backingplate with a pattern of pockets or channels, similar to the embodimentwith shown in FIG. 27E, but without the springs.

FIG. 27G is a bottom view of the alternative webbing or backing platewith a pattern of pockets or channels as shown in FIG. 27F.

FIG. 27H is a front view of the alternative webbing or backing platewith a pattern of pockets or channels as shown in FIG. 27F.

FIG. 27I is a top view of the alternative webbing or backing plate witha pattern of pockets or channels as shown in FIG. 27F.

FIG. 27J is a back view of the alternative webbing or backing plate witha pattern of pockets or channels as shown in FIG. 27F.

FIG. 27K is a left view of the alternative webbing or backing plate witha pattern of pockets or channels as shown in FIG. 27F.

FIG. 27L is a right view of the alternative webbing or backing platewith a pattern of pockets or channels as shown in FIG. 27F.

FIG. 28 is a top view of a mattress having design elements of theinvention and with the top layers removed for illustration.

FIG. 29 is a top view of another mattress having design elements of theinvention and with the top layers removed for illustration.

FIG. 30A is a perspective view of part of another spring core.

FIG. 30B is an inverted perspective view of the spring cap shown in FIG.30A.

FIG. 30C is a perspective view of the spring cap shown in FIG. 30A.

FIG. 30D is a bottom view of the spring cap shown in FIG. 30C.

FIG. 30E is a front view of the spring cap shown in FIG. 30C.

FIG. 30F is a top view of the spring cap shown in FIG. 30C.

FIG. 30G is a back view of the spring cap shown in FIG. 30C.

FIG. 30H is a left view of the spring cap shown in FIG. 30C.

FIG. 30I is a right view of the spring cap shown in FIG. 30C.

FIG. 31 is an inverted perspective view of part of another spring core.

FIG. 32A is a bottom perspective view of the spring cap shown in FIG.31.

FIG. 32B is a bottom perspective view of the spring cap shown in FIG.32A.

FIG. 32C is a perspective view of the spring cap shown in FIG. 32A.

FIG. 32D is a bottom view of the spring cap shown in FIG. 32C.

FIG. 32E is a front view of the spring cap shown in FIG. 32C.

FIG. 32F is a top view of the spring cap shown in FIG. 32C.

FIG. 32G is a back view of the spring cap shown in FIG. 32C.

FIG. 32H is a left view of the spring cap shown in FIG. 32C.

FIG. 32I is a right view of the spring cap shown in FIG. 32C.

FIG. 33A is a perspective view of part of another spring core.

FIG. 33B is a top perspective view of another spring cap.

FIG. 33C is a perspective view of the spring cap shown in FIG. 32A.

FIG. 33D is a bottom view of the spring cap shown in FIG. 33C.

FIG. 33E is a front view of the spring cap shown in FIG. 33C.

FIG. 33F is a top view of the spring cap shown in FIG. 33C.

FIG. 33G is a back view of the spring cap shown in FIG. 33C.

FIG. 33H is a left view of the spring cap shown in FIG. 33C.

FIG. 33I is a right view of the spring cap shown in FIG. 33C.

FIG. 34A is an inverted perspective view of part of another spring core.

FIG. 34B is a top perspective view of the spring cap shown in FIG. 34A.

FIG. 34C is a perspective view of the spring cap shown in FIG. 32A.

FIG. 34D is a bottom view of the spring cap shown in FIG. 34C.

FIG. 34E is a front view of the spring cap shown in FIG. 34C.

FIG. 34F is a top view of the spring cap shown in FIG. 34C.

FIG. 34G is a back view of the spring cap shown in FIG. 34C.

FIG. 34H is a left view of the spring cap shown in FIG. 34C.

FIG. 34I is a right view of the spring cap shown in FIG. 34C.

FIG. 35A is an inverted perspective view of part of another spring core.

FIG. 35B is a top and rear perspective view of the spring cap shown inFIG. 35A.

FIG. 35C is a top and front perspective view of the spring cap shown inFIG. 35A.

FIG. 35D is a perspective view of the spring cap shown in FIG. 35A.

FIG. 35E is a bottom view of the spring cap shown in FIG. 35D.

FIG. 35F is a front view of the spring cap shown in FIG. 35D.

FIG. 35G is a top view of the spring cap shown in FIG. 35D.

FIG. 35H is a back view of the spring cap shown in FIG. 35D.

FIG. 35I is a left view of the spring cap shown in FIG. 35D.

FIG. 35J is a right view of the spring cap shown in FIG. 35D.

FIG. 36A is a section view of another mattress.

FIG. 36B is bottom perspective view of part of the spring core and toppad of the mattress shown in FIG. 36A.

FIG. 36C is a perspective view of the top pad of the mattress shown inFIG. 36A, without the springs.

FIG. 36D is a bottom view of the top pad shown in FIG. 36C.

FIG. 36E is a front view of a projection or boss shown in FIG. 36C.

FIG. 36F is an enlarged view of a spring cap shown in FIG. 36E.

FIG. 36G is a top view of the top pad shown in FIG. 36C.

FIG. 36H is a back view of the top pad shown in FIG. 36C.

FIG. 36I is a left view of the top pad shown in FIG. 36C.

FIG. 36J is a right view of the top pad shown in FIG. 36C.

FIG. 37A is a section view of another mattress.

FIG. 37B is bottom perspective view of part of the spring core and toppad of the mattress shown in FIG. 37A.

FIG. 37C is a perspective view of the top pad of the mattress shown inFIG. 37A, without the springs.

FIG. 37D is a perspective view of the top pad of the mattress shown inFIG. 37A, without the springs.

FIG. 37E is a bottom view of the top pad shown in FIG. 37C.

FIG. 37F is a front view of the top pad shown in FIG. 37C.

FIG. 37G is an enlarged view of a boss positioned within a recess shownin FIG. 37F.

FIG. 37H is a top view of the top pad shown in FIG. 37C.

FIG. 37I is a back view of the top pad shown in FIG. 37C.

FIG. 37J is a left view of the top pad shown in FIG. 37C.

FIG. 37K is a right view of the top pad shown in FIG. 37C.

FIG. 38A is a perspective view of the springs and spring caps of thespring core in a stacked column for storage or transport.

FIG. 38B is a perspective view of the springs and spring caps of thespring core in a stacked column for storage or transport, as shown inFIG. 38A.

FIG. 38C is a bottom view of the stacked column of springs and springcaps shown in FIG. 38B.

FIG. 38D is a front view of the stacked column of springs and springcaps shown in FIG. 38B.

FIG. 38E is a top view of the stacked column of springs and spring capsshown in FIG. 38B.

FIG. 38F is a back view of the stacked column of springs and spring capsshown in FIG. 38B.

FIG. 38G is a left view of the stacked column of springs and spring capsshown in FIG. 38B.

FIG. 38H is a right view of the stacked column of springs and springcaps shown in FIG. 38B.

FIG. 39A is a perspective view of the springs and spring caps of asmaller size mattress in a stacked column for storage or transport.

FIG. 39B is a bottom view of the stacked column of springs and springcaps shown in FIG. 39A.

FIG. 39C is a front view of the stacked column of springs and springcaps shown in FIG. 39A.

FIG. 39D is a top view of the stacked column of springs and spring capsshown in FIG. 39A.

FIG. 39E is a back view of the stacked column of springs and spring capsshown in FIG. 39A.

FIG. 39F is a left view of the stacked column of springs and spring capsshown in FIG. 39A.

FIG. 39G is a right view of the stacked column of springs and springcaps shown in FIG. 39A.

FIG. 40A is a perspective view of the springs and spring caps of alarger size mattress in two stacked columns in a container, for storageor transport.

FIG. 40B is a perspective view of the springs and spring caps of thespring core in a stacked column for storage or transport, as shown inFIG. 40A.

FIG. 40C is a bottom view of the stacked column of springs and springcaps shown in FIG. 40B.

FIG. 40D is a front view of the stacked column of springs and springcaps shown in FIG. 40B.

FIG. 40E is a top view of the stacked column of springs and spring capsshown in FIG. 40B.

FIG. 40F is a back view of the stacked column of springs and spring capsshown in FIG. 40B.

FIG. 40G is a left view of the stacked column of springs and spring capsshown in FIG. 40B.

FIG. 40H is a right view of the stacked column of springs and springcaps shown in FIG. 40B.

FIG. 41 is a perspective view of another spring cap.

FIGS. 42A to 44 are perspective views of a sequence of assembly of thespring element shown in FIG. 41.

FIG. 42B is a perspective view of the element shown in FIG. 42A.

FIG. 42C is a bottom view of the element shown in FIG. 42B.

FIG. 42D is a front view of the element shown in FIG. 42B.

FIG. 42E is a top view of the element shown in FIG. 42B.

FIG. 42F is a back view of the element shown in FIG. 42B.

FIG. 42G is a left view of the element shown in FIG. 42B.

FIG. 42H is a right view of the element shown in FIG. 42B.

FIGS. 45 to 47 are schematic diagrams of actuators acting on a mattresselement.

FIG. 48 is a top view of a mattress divided into separate sectionsmoveable vertically.

FIG. 49 is a section view of the mattress of FIG. 48.

FIGS. 50-54 are section views of operations of a mattress havingseparate sections movable vertically.

DETAILED DESCRIPTION

FIG. 1a and FIG. 1b are respectively a perspective view and a sectionalview schematically illustrating an elastic module 100 having a spring 5,and an elastic outer covering layer 1 formed of e.g., polyurethanesponge and surrounding the spring completely or partially. The spring 5is disposed in the outer covering layer 1 in such a manner that thespring 5 can be substantially static relative to the outer coveringlayer 1, so that the spring moves with the outer covering layer 1. Theelastic module 100 may be made in at least two ways.

In the first way mainly by utilizing a foaming process, the spring 5 andthe outer covering layer 1 are simultaneously integrally formed witheach other. The specific operation steps can be similar to those of thefoaming process for a vehicle seat. In brief, the spring 5 is nested ona mold core located in a middle of a mold, like a foam box. Since theelastic deformation of foam-molded polyurethane sponge cannot be readilyrecovered, the elastic force of the spring 5 may be adverselyinfluenced. Nesting the spring 5 over the core avoids this undesirablepossibility. In this first way the integrally formed spring 5 and outercovering layer 1 are obtained when the foaming or molding process iscompleted.

In the second way, the foaming process is first used to make the outercovering layer 1 of polyurethane foam material, and then the middleportion of the foaming-formed outer covering layer is hollowed out. Thevolume of the hollowed region may be adjusted based on the number of thesprings 5 to be included in the elastic module. Next, the springs 5 areplaced in the hollowed region. To form an interference fit between thesprings 5 and the outer covering layer 1, the dimension of the hollowedregion should be smaller than the space occupied by the springs 5. Inthis embodiment, the spring may be attached to the outer covering layer1, or it may be only contained within the outer covering layer 1.

As shown in FIG. 9a -FIG. 9 b, four springs 5 are disposed in one outercovering layer 1, with each of springs 5 preferably spaced apart by aportion of the outer covering layer 1. In other words, in the first wayof the integral foaming process, the number of the cores is preferablyequal to the number of springs 5, while in the second way of forming ahollow portion by removing a portion of a foaming body, a portion ofpolyurethane foaming body is preferably retained between each of thehollow portions, providing a dividing wall between adjacent springs.

In either case the spring 5 should have a certain pre-load orpre-tension after the mounting or assembling is completed, so as tobetter achieve a relatively static relation of the springs with theouter covering layer 1.

In order to detachably assemble elastic modules 100, a user may purchaseelastic modules 100 in a certain number conforming to a dimension of adesired furniture, as well as a fabric cover having a dimension matchingwith the volume of the certain number of the elastic modules 100, like acouch cover, a bed cover, etc. The user can then place the elasticmodules 100 into the cover, arrange them in a certain mode, and finallyclose the cover (via a zipper, snaps, hook and loop tape, etc.) toprovide an integral and detachable bed mattress. Ideally, the elasticmodules 100 are preferably not movable in horizontal directions afterbeing placed into the cover; in other words, the elastic modules 100will remain in place relative to the cover.

To combine a plurality of elastic modules 100 more firmly as a whole,the surface of the outer covering layer 1 may be provided withnon-permanent connection structures, like straps tape, snap buttons,hooks 20, etc., which are for example sewn on the outer covering layer1. In this way, a tighter connection among the elastic modules 100 willbe created, making the couch, mattress, etc. more comfortable.

FIG. 10a -FIG. 10d show another example of a plurality of springsarranged simultaneously within one elastic module 100. FIG. 10a is a topview of the elastic module 10 (or it may be a bottom view, depending onhow an end member 2 is disposed relative to the outer covering layer 1).In FIGS. 10a-10d , the six springs 5 of the same dimension are mountedas described above. The dimensions or configurations of these sixsprings may be different. FIG. 10b is a side view of an elastic module100 comprising six springs 5. FIG. 10c and FIG. 10d are respectively aside view and a top view of a spring pad assembled from the elasticmodules 100.

Simultaneously mounting a plurality of springs 5 in one elastic module100 has the following advantages: as compared to an elastic module 100having a small volume (e.g. an elastic module 100 having only one spring5 of the same or similar dimensions), when a user needs to assemble alarger spring pad, like a double mattress, from the elastic modules 100,this multi-spring elastic module 100 having a relatively large volumeachieves the purpose of easy assembly or disassembly and simultaneouslysaves time spent on assembling and dissembling the elastic modules 100.This is because, in the case that the spring pad has an identical orsimilar volume, the number of the required elastic modules 100 isreduced, and the required assembling or disassembling steps are reducedaccordingly. Based on a desired size and characteristics, the elasticmodules 100 can be provided with for example two, four, six, eight oreven more springs.

Although the elastic modules 100 are shown as a cube or cuboid, theelastic modules 100 may be for example a triangular or pyramid shaped.In this case, the number of springs 5 may be one, three, five, etc.

Preferably, the spring 5 is a spiral spring. For example, the spring 5as shown in FIG. 4a is a middle-portion-convex spiral spring, the one asshown in FIG. 4b is a middle-portion-concave spiral spring, and the oneas shown in FIG. 4c is a truncated conical spiral spring. The spring 5may be preferably any one of a cylinder spiral spring, a conical spiralspring, a middle-portion-convex or concave spiral spring, or a spiralspring formed by nesting a left-handed spring and a right-handed springtogether. In the spiral spring formed by nesting a left-handed springand a right-handed spring together, the dual-spring configuration avoidsthe defect that a single spring is vulnerable to be broken and it mayhave improved elastic performance. In practice, any type of springcapable of solving the technical problem may be used.

As shown in FIG. 3 the elastic module 100 may have an end member 2attached to a lower end of the outer covering layer 1, with the endmember 2 formed thereon with a module connecting structure capable ofallowing a plurality of elastic modules 100 to be detachably coupledwith one another. Herein, “an upper end face” and “a lower end face” areoriented relative to a longitudinal (vertical) axis of the spring 5.

In this embodiment, the spring 5 and the outer covering layer 1 areformed as one integral piece as described above. After the elasticmodule 100 is formed, an end member is provided. A bottom end of thespring 5 may abut against or attach to the end member 2, i.e., the endmember 2 here may act as a support for the spring as shown in FIG. 4a-FIG. 4 c. The end member 2 may be a rigid disk, ring or plate, althoughin some designs as described below, the end member 2 is somewhatflexible.

In the embodiment in FIGS. 7a -7 d, the module connecting structure maycomprise a recess 2 a formed on one side wall of at least one pair ofside walls of the body of the end member 2, and a protrusion 2 b formedon the opposite side wall. The protrusion 2 b is adapted to engage therecess 2 a of the end member 2 of an adjacent elastic module. The recess2 a and protrusion 2 b are attached to each other using a snap fit or ashaped fit, such as a dovetail fit. The recess 2 a and the protrusion 2b both extend horizontally, perpendicular to the longitudinal (vertical)axis of the spring 5. This module connecting structure is advantageousfor assembling the elastic modules 100 horizontally, alongside eachother, on a floor or on frame.

In a further embodiment, the module connecting structure may comprise amounting hole 4 formed on the body of the end member 2, and the mountinghole 4 is capable of cooperating with a separate locking piece 3 (FIG. 3and FIG. 7a -FIG. 7d ), such that the plurality of elastic modules 100can be detachably coupled together.

In this context, a mounting hole 4 may be preferably distributedsymmetrically at four corners of the end member 2, as shown in FIG. 3.When two elastic modules 100 are transversely assembled side-by-side, asshown in FIG. 3, the locking piece 3 is fixed or snap-connected to themounting hole 4 by using a pin, screw, etc. or only by using the lockingpiece 3 per se, such that these two elastic modules 100 are connected.Any number of elastic modules 100 can be assembled horizontallyside-by-side into a pad or mattress, as shown in FIG. 6. The lockingpiece 3 is described below in detail with reference to FIG. 17.

The end member 2 may have a shape as shown in FIG. 2, FIG. 3, FIG. 4a-FIG. 4 b, or a different shape. The end member 2 may directly contactthe ground or frame, that is, the assembled spring pad can be directlyplaced on a horizontal contact face with the end member 2.

The end member 2 as shown is substantially flat or planar, but it mayalso be in the form of a frame or of any other appropriate shape so longas it can perform the function of connecting with another elasticmodule. For use on a frame the end member 2 may have certain flexibilityto enable the spring pad 100 a, 100 b (e.g. the bed mattress in FIG. 15a-FIG. 15b and the couch cushion in FIG. 16a -FIG. 16b ) to adaptivelymatch the curved surfaces, if any, of the bed frame, couch frame, etc.The bottom coil 18 of the spring 5 can rest on, or be attached to, theend member 2.

As shown in FIGS. 8a and 9b , in addition to transverse (or horizontal)assemblies, the elastic modules 100 can be stacked or assembledvertically as well. For example, small elastic modules 100 can be builtup horizontally and vertically to provide a pad or mattress having adesired height.

An end member 2 may be provided on both the top and bottom surfaces ofthe outer covering layer. In this case, the module connecting structuremay comprise a recess formed at an edge of an outward end face 1 a (FIG.4a -FIG. 4c ) of one of the two end members 2, and a protrusion formedon an outward end face 1 b (FIG. 3) of the other end member, and whereinboth the recess and the protrusion extend substantially vertically. Bysnapping the recess on the outward end face of the end member 2 of oneelastic module 100 with the corresponding protrusion on the outward endface of the end member on another elastic module, the two elasticmodules may be vertically mounted or stacked. In this embodiment, therecess and the protrusion for forming the module connecting structure issimilar to those of the recess 2 a and the protrusion 2 b as shown inFIG. 7a -FIG. 7 d.

The end member 2 may be made of polyurethane sponge, or metal orplastic. Preferably, if used, the sponge for producing the end member 2is denser and harder than the outer covering layer 1, such that the endmember forms is sufficiently strong and rigid connection to allow endmembers of adjacent elastic modules to securely form a spring pad ormattress. In this case, the recess 2 a and the protrusion 2 b of themodule connecting structure are formed of polyurethane sponge.

Now turning to FIG. 11a -FIG. 11 b, FIG. 12a -FIG. 12b and FIG. 13a-FIG. 13 b, the surface of the outer covering layer 1 may be formed withuniformly distributed concave holes 6. FIG. 11a -FIG. 11b illustrateelongated rectangle-like holes 6 extending vertically on the sides ofthe elastic module. FIG. 12a -FIG. 12b illustrate concave holes 6oriented horizontally on the sides of the elastic module. FIG. 13a -FIG.13b illustrate honeycomb-shaped concave holes 6, optionally on all sidesof the elastic module. The concave holes 6, if used, reduce restrictionsof the outer covering layer 1 on the movement of the spring 5 in eachorientation so as to optimize the elastic performance of the spring 5,thereby providing better comfort to the user.

Referring to FIG. 14, a storage state of unassembled or disassembledelastic modules 100 is shown. The separate elastic modules 100 are shownin a compressed state within a storage space or container 8, therebygreatly reducing the storage space occupied by the elastic modules. Whenthe consumer purchases the elastic modules 100 they may be packaged in acompressed state. Hence they are easily loaded into a vehicle andtransported to his/her residence. The elastic modules 100 will expandwhen removed from the container 8. They can then be assembled togetherwithout tools. Similarly, the elastic modules can be disassembled andstored temporarily, or moved from one place to another place, byfollowing the reverse procedure. Each elastic module 100 can be detachedfrom adjoining elastic modules, compressed and stored in the container8. Compared to traditional furniture, the volume of the compressedelastic modules can be advantageously reduced by 40-90%, and thereforelowers transport costs and storage space requirements.

Spring pads or mattresses 100 a, 100 b formed of the elastic modules 100are also provided. The elastic module 100 may include an elastic outercovering layer 1 formed of polyurethane couch sponge, at least onespring 5 disposed in the middle of the outer covering layer 1, an endmember 2 attached onto at least one end face of the outer covering layer1, and a mounting hole 4 formed on the body of the end member 2. As apreferable manner, the spring pad further comprises an separate lockingpiece 3 which can be connected with the mounting hole 4 via for examplea screw, etc., or can engage the mounting hole 4 in any appropriatemanner, such that a plurality of elastic modules 100 can be detachablycoupled with one another.

A cloth, fabric or leather cover may be provided around the outercovering layer 1.

With reference to FIG. 15a -FIG. 15d and FIG. 16a -FIG. 16 b, specificapplication of the spring pads 100 a, 100 b are illustrated.

FIG. 15a -FIG. 15d schematically illustrate a furniture pad 100 a formedof elastic modules 100. The elastic modules 100 may be directly laidflat for example on a floor with the end members 2 at the bottom of theelastic modules 100 on the floor, or may they be mounted to a bed frame100 a 1 using frame connecting elements 100 a 2 such as clamps, clips,straps, etc. The dimension of the assembled elastic modules 100adaptively matches the bed frame 100 a 1. FIG. 15a schematicallyillustrates the assembling process of the spring pad 100 a with the bedframe 100 a 1, FIG. 15b shows the spring pad 100 a after the assembly iscompleted, and FIG. 15c and FIG. 14d are respectively a side view and atop view of the spring pad 100 a.

FIG. 16a -FIG. 16b schematically illustrate a spring pad 100 b formed ofelastic modules 100 for use as a couch pad. As described above, theelastic modules 100 may be directly laid flat for example on a floor viathe end members 2 at the bottom of the elastic modules 100, or may bemounted to a couch frame 100 b 1 by using frame connecting elements 100b 2. Here, the dimension of the assembled spring pad 100 b adaptivelymatches the couch frame 100 b 1. FIG. 16a schematically illustrates anassembling process of an exemplary couch cushion 100 b and a couch frame100 b 1, and FIG. 16b schematically illustrates a perspective view of acouch assembled from the spring pad 100 b.

To provide furniture having a backrest slightly in an arc shape, like acouch, the end member 2 may be preferably made of an elastic material,such as rubber, so that it has certain flexibility. Preferably, the endmember 2 may be a relatively thin plastic sheet. Referring to FIG. 16b ,in this case, the spring pad 100 b uses a flexible end member 2. Theelastic outer covering layer 1 can fit with a backrest portion of theframe 100 b 1 with almost no gaps to complete the assembling, offeringmore comfortable sitting and lying experiences to the user. In otherembodiments the end member 2 is rigid.

The elastic modules 100 may have the same or different sizes and shapes.The elastic modules 100 need not be identical to each other, so long asthey can be assembled together as described above.

As shown in FIG. 17, the spring pad assembled from the elastic modules100 may be folded to form a configuration of the couch as displayed inFIG. 17. To allow for folding, firstly, the elastic modules 100 areconnected in a row having a desired width of the spring pad 100 c. Then,based on the desired length or height, multiple rows are assembled andattached together, to form, for example a backrest portion and seatcushion portion. In this example with the backrest portion having fourrows and the seat cushion portion also having four rows, the four rowsof the elastic modules of the back portion are connected with oneanother via the module connection structures as described above, and thefour rows of the elastic modules of the cushion portion are connectedwith one another via the module connection structures also as describedabove. Finally, an articulated connection is preferably used between theelastic modules for engaging the backrest portion with the seat cushionportion, or any other connection allowing the backrest portion and thecushion portion to be pivoted relative to each other may be used. Otherfolding connections may of course also be used.

Now turning to FIG. 18 a plurality of elastic modules 100 are mounted toa support frame 7 by clips 100 b 2 or equivalent designs similar to theframe connecting elements 100 a 2 (FIG. 15a -FIG. 15b and FIG. 16a ),which enables the elastic module 100 to be detachably connected to thesupport frame 7 and kept relatively fixed in place on the support frame.Alternatively, clips may be arranged in a center or at an edge of theend member 2, or a plurality clips may be arranged symmetrically at fourcorners of the end member 2. When elastic modules 100 are to be mountedonto the support frame 7, the user only needs to for example snap orattach the clips onto a frame stem of the support frame 7 (e.g. 7 c inFIG. 19, as well as the frame stem 100 a 3 in FIG. 15a and the framestem 100 b 3 in FIG. 16a ) to complete the connection.

In FIG. 18, the elastic modules 100 may, as described above, comprise amodule connecting structure for detachably connecting them. In this way,each elastic module 100 can be mounted on the support frame 7, and alsobe connected to adjacent elastic modules. Alternatively, the connectionbetween adjacent elastic modules 100 can be omitted, and each elasticmodule may be directly mounted on the support frame 7 via the clips 2 c,without attaching the modules 100 to each other.

FIG. 19 schematically illustrates an example of a clip 2 c and a lockingpiece 3. A frame stem 7 c is part of the support frame 7. The clip 2 cin the example shown has a semi- cylindrical hollow portion formingopposed flex arms, to clip or clamp onto the frame stem or tube 7 c. Theclip 2 c also has a sheet or plate portion joined to thesemi-cylindrical hollow portion, for engaging with the locking piece 3.The semi-cylindrical hollow portion has an opening adapted to clip ontothe frame stem 7 c. The sheet portion may have four protrusions. Thelocking piece 3 may have a blind hole protruding upwardly along thedotted line in FIG. 19, and each locking piece 3 is formed with two suchportions.

During assembling, each of the two blind holes of the locking piece 3 isaligned and engaged with one protrusion on the sheet portion of the clip2 c, for example, using a detachable interference fit. The sheet portionmay be simultaneously connected with two locking pieces 3, and the blindhole-like portion of the locking piece 3 can be inserted into themounting hole 4 in the end member 2, so as to allow two elastic modulesto be engaged with each other.

In addition, the frame connecting element 100 a 2 in FIG. 15a -FIG. 15band the frame connecting element 100 b 2 in FIG. 16a may have the sameor similar configuration as the clip 2 c.

In FIG. 18, or in the case that the elastic module 100 has an end member2 only on one end face thereof, the other end face of the elastic module100 opposite the end face provided with the end member 2 may have acurvature 100 d 1 determined based on ergonomics, as shown in FIG. 18.This curvature conforming to the ergonomics enables a contact surfacefitting with a back structure of a human body to be directly formedimmediately after the assembly of a plurality of elastic modules 100 iscompleted, thereby making the user comfortable.

FIG. 20a -FIG. 20c are schematic diagrams of a further embodiment whichillustrate that the spring 5 is partially covered by the outer coveringlayer 1, and the elastic modules 100 are assembled via the recesses 2 aand protrusions 2 b to form an integral spring pad.

FIG. 21a -FIG. 21d are schematic diagrams of a further embodiment whichillustrate that the spring 5 is partially covered by the outer coveringlayer 1, and the elastic modules 100 are assembled via module connectionstructure as shown therein to form a furniture pad or mattress. Thisembodiment differs from FIG. 20a -FIG. 20c in that the module connectingstructure is comprised of protruding ridges or hooks 3 a, 3 b formed atopposite edges of the end member 2. In this embodiment, one outercovering layer simultaneously covers a plurality of springs, forexample, four springs 5 as shown in the figures.

A decorative or protective cloth cover, etc. may be used on the outersurface cover of the couch or bed assembled from the elastic modules100.

The elastic module enables independent configurations to meet the needsof the user. The elastic modules may be assembled to form furniturewherein vertical deflection of one elastic module has little or noinfluence on other elastic modules of the spring pad or mattress. Theindependent configuration is also helpful for cleaning and replacing theelastic modules. Specifically, is elastic modules in the spring pad arestained or damaged, they can be easily replaced without need forreplacing the entire spring pad.

As shown in FIGS. 22 and 23, a mattress 130 has a spring core 132 madeup of individual spring assemblies 145 attached to each other. Eachspring assembly includes at least one spring 134 and a spring cap 144. Atop pad 136 is placed on top of the spring core 132. Side pads 138 arepositioned around the perimeter of the spring core. The top pad 136 andthe side pads 138 may be a foam material, typically 2 to 8 cm thick. Inthe example shown four separate side pads 138 are used. However, asingle side pad 138 wrapped around the corners of the spring core 132and/or the top pad 136 may also be used. The side pad 138 may optionallybe omitted from one or more sides of the mattress depending on itsintended use. As shown in FIGS. 22 and 23, the mattress 130 has no rigidframe or side pieces, each spring assembly is individually attachable toadjoining spring assemblies, and the springs themselves are attached tothe spring caps, but not to each other. Similarly, the mattress needs nointernal ribs, strips or other structures to attach the springs.

The side pads 138 may be attached to the top pad 136 via an adhesive,fasteners, Velcro® hook and loop tape or an equivalent. A cloth orfabric cover 140 is generally provided over the top pad 136 and the sidepads 138. The cover 140 may optionally also cover the bottom of themattress. As shown in FIG. 23, a zipper 142 may be provided on the cover140 at the perimeter of the top pad 136 to better facilitateinstallation and removal of the cover. Also as shown in FIG. 23, thespring caps may rest on the floor.

The springs 134 may be metal, e.g., steel coil springs generally havinga single spiral of wire, although in some embodiments multiple spiralsmay be used. The springs 134 are conical, tapering from a largerdiameter bottom coil 160 to a smaller diameter top coil 58. The bottomcoil may have a diameter of 5 to 15 cm, with the top coil typicallyhaving a diameter of 30 to 90% or 45 to 70% of the bottom coil. In mostdesigns the springs 134 taper conically and uniformly, and all of thesprings are the same.

Referring momentarily also to FIGS. 28 and 29 the number of springassemblies 145 used will vary with the size and firmness of themattress. The mattress as shown in the Figures may have 11 rows and 6columns of spring assemblies 145. The spring assemblies may be in arectangular array as shown in FIG. 28, or in a diamond pattern as shownin FIG. 29, where the spring assemblies are more closely packed. Thespring assemblies or elastic modules of FIGS. 1-21, of any type, mayalso be arranged in a triangle pattern, a rectangle pattern, or ahexagon pattern.

As shown in FIG. 28, each interior spring assembly 145 (excluding thecorners) is attached to four other adjacent spring assemblies, while inFIG. 29 each interior spring assembly is attached to six other adjacentspring assemblies. Correspondingly, in FIG. 28, each exterior orperimeter spring assembly 145 is attached to three other adjacent springassemblies, whereas in FIG. 29 each perimeter spring assembly isattached to four other adjacent spring assemblies. While a standardconventional mattress may have about 300 springs, the number of springsin the present mattress is reduced on reliance of its other designfeatures.

Turning to FIG. 24A, the bottom coil of the spring 134 is dimensioned tofit into the spring cap 144. A top segment 159 of the spring 134 extendsacross the top coil of the spring, forming a diameter or a chord of thetop coil. Each spring cap 144 is generally ring-shaped with a largeround central opening in the body 149 of the spring cap. FIG. 25 showspart of a spring core 132 formed by attaching spring caps 144 to eachother.

FIG. 24B shows an alternative design using a spring clip 146 instead ofa spring cap 144 to attach the springs together to form a spring core132. The spring clip 146 may be provided as a block of metal or plastichaving a first slot 147 and a second slot 148. The bottom coil 160 ofthe spring 134 is placed into the first slot 147 and the bottom coil ofan adjacent spring is placed into the second slot 148. The bottom coils160 may optionally snap into the slots. In some designs one or more ofthe spring clips 146 may be permanently attached to the spring 134.Alternatively, the spring clips 146 may be separately provided andinstalled as needed. As shown in FIGS. 26 and 28, if the spring clips146 are used, generally each spring 134 is attached to four adjacentsprings, using four spring clips 146. Various other forms of springclips 146 may of course also be used, as any device capable of securingthe springs together may serve as a spring clip 146.

Referring to FIG. 27A, the mattress 130 may use spring caps 150 that areattached to a webbing or backing sheet 154. In the example of FIG. 27Athe webbing is provided as a grid having equally spaced apart throughopenings. The webbing 154 may be a thin flexible material, so that itcan be rolled up or folded when the mattress is not in use.Alternatively, the webbing 154 may be a rigid plate. In FIG. 27A thespring caps 150 are permanently attached to the webbing 154, although inother designs the spring caps may be removable from the webbing 154. Thespring cap 150 has an elongated flat base 152 with first and second arcsections 151 and 155 projecting up from the base 152. The arc sections151 and 155 may both have inward facing grooves 153 or both have outwardfacing grooves 157. The grooves are adapted to receive and hold thebottom coil of the spring 134. If the groves are both inward facinggrooves, the bottom coil of the spring is first compressed and pushedinto the grooves, and then released to expand radially outwardly intothe inward facing grooves. If the grooves are both outer facing grooves,the bottom coil of the spring is first expanded, placed over the arcsections, and then released to compress inwardly into the outward facinggrooves. In the design shown, all of the spring caps 150 are alignedparallel to each other, and at an acute angle (e.g. 35 to 55°) relativeto the rows and columns of the webbing 154.

FIG. 27B shows a similar design using a solid webbing 56 without throughholes. The spring caps 161 in FIG. 27B have spaced apart lugs 162 on aflat base 152, with an outward-facing groove 163 on each lug. The designof FIG. 27B may have elements assembled and used in the same way asdescribed above relative to FIG. 27A. With the spring caps 150 and 161attached (removably or permanently) to the webbing 154 and 156 in FIGS.27A and 27B, respectively, the spring caps are not attached to eachother, as in FIGS. 22-29.

FIG. 27C shows an alternative design having a webbing 60 with a patternof pockets or channels 61. The pocket 61 has a diameter matching thediameter of the bottom coil of the spring 134. The pocket 61 forms anarc generally of 220 to 330 degrees. The pocket 61 has an open end 62and a closed end 63, although is some embodiments the pocket 61 may havetwo open ends 63. The pockets 61 may be stitched or sewn using twolayers of webbing material. The springs 134 are installed onto thewebbing 60 by inserting the leading free end 64 of the bottom coil ofthe spring into the open end 62 of the pocket, and rotating the spring134 clockwise, typically about ¾ turn, until the spring 134 is fullyinstalled, optionally with the leading free end 64 coming to a stopagainst the closed end 63 of the pocket 61. The spring 134 is thenattached to the webbing 60. The spring 134 is removed using the reversesequence, providing a quick and easy way to assemble a spring core. Withthe springs removed, the webbing 60 may be rolled or folded into acompact form. FIG. 27D shows several springs for use with the webbing 60with a pattern of pockets or channels 61 as shown in FIG. 27 C arestacked together.

As shown in FIG. 30B, an alternative spring cap 164 has a generallyhexagonal shape, with a coil floor 165 adjoining a coil wall 166 on thetop side of the spring cap. Inward tabs 167 extend radially inwardlyover the coil floor 165 to help retain the bottom coil 160 of the spring134 onto the spring cap 164. The diameter of the coil wall 166 and thecircular opening through the spring cap 164 defined by coil floor 165will vary with the specific springs used, with typical diameters rangingfrom 5 to 15 cm. The inward tabs 167 may be provided only on one side ofthe coil floor 165 to allow for easier installation of the spring 134onto the spring cap 164. Side tabs 168 and side slots 169 may beprovided on alternating sides of the spring cap 164. Each side tab 168is dimensioned to fit into a side slot 169 of an adjacent or adjoiningspring cap 164.

The spring cap 164 may also have a side post 178 projecting radiallyoutward from an apex or corner between two sides of the spring cap 164.A corresponding side socket or recess 180 is located opposite from theside post 178. The side post 178 is dimensioned to fit into a recess ofan adjacent or adjoining spring cap 164. The spring cap 164 is flat witha height of about 3 to 15 mm, made of metal or plastic. FIG. 30A shows aspring core 132 formed using spring assemblies 145 having the spring cap164 shown in FIG. 30B. The side post 178, if used, helps to hold thespring caps 164 in a flat plane when assembled into a spring core 132.Apart from the side tabs 168 and side slots 169, the six sides are flatand smooth to allow adjoining spring caps 164 to be closely assembled toeach other as shown in FIG. 30A.

Turning to FIGS. 31, 32A and 30B, another spring cap 171 has a hexagonalbody, a coil floor 165, a coil wall 166, and tabs 167, and is otherwisesimilar to the spring cap 164 shown in FIG. 30B, without any side post178, and except as described below. The spring cap 171 has side plates172 extending radially outward from adjacent sides of the spring cap171. A plate hook 173 projects upward from the top side of each sideplate 172. The plate hook 173 has a height and curvature selected tocorrespond to the inside diameter of the bottom coil 160 of the spring134. Alignment holes 177 may be provided through each side plate 172 tobetter allow for aligning the spring caps 171 into a stacked column, asshown in FIG. 39 and discussed below. Pairs of ring hooks 174 areprovided on the bottom of the spring cap, on the sides of the spring cap171 opposite from the side plates, adjacent to corners of the spring cap171. Pairs of notches 176 are provided on opposite sides of each sideplate 172, with the notches 176 positioned and adapted to engage withthe ring hooks 174 of an adjoining spring cap 171.

FIG. 31 is a bottom view of a spring core 32 formed using springs 134and spring caps 171. The bottom coil 160 of the spring 134 is held inthe spring cap 171 between the coil tabs 167 and the coil floor 165. Ifthe spring 134 is rotated slightly when pressed onto the spring cap 171,the bottom coil 160 may momentarily slightly contract duringinstallation and then return to its original diameter. In this case,friction may also help to hold the bottom coil 160 in place via a radialoutward spring force holding the bottom coil 160 against the coil wall166. The plate hooks 173 engage with the inner surface of acorresponding segment of the opening of the spring cap of an adjoiningspring assembly, e.g., at the lead line of element 166 in FIG. 32B. Thering hooks 174 engage the notches 176 of adjoining spring caps 171. Asshown in FIG. 32B, ramps 175 at the top of spring cap 171 aligned withthe notches 176 may be used to guide the ring hooks 174 into the notches176. The ring hooks 174 and the plate hook 173 have a limited amount ofresiliency or flexibility due to their design and dimensions, and alsooptionally resulting from resiliency characteristics of the materialused to manufacture the spring cap 171, for example a plastic material.The plate hooks 173 and the ring hooks 174 may snap into place duringassembly of the spring core.

Referring to FIG. 33B, another spring cap 184B has a coil floor 165, acoil wall 166 and coil tabs 167 as described above. The spring cap 184Bmay also have a spring end socket 185 to hold the end of the wire of thespring 134. A pair of split pins 186 project outward from bosses 188 ona first side of the spring cap 184B. A corresponding pair of pin holes187 extend through bosses 188 on a second side of the spring cap 184B,opposite from the first side, with the pin holes 187 aligned with thesplit pins 186. The outer end of each split pin 186 may be tapered orangled. FIG. 33A shows a part of a spring core 132 formed using springs134 and spring caps 184A, which are the same as the spring caps 184B butfurther include corner tabs 190. The corner tabs 190, if used, may helpthe spring cap 184A rest flat on the floor. The corner tabs 190 may alsostiffen the spring cap 184A against twisting and bending, and also helpto keep the spring caps 184A aligned when stacked into a column forstorage, as described below.

As shown in FIGS. 33A and 33B, the spring core 132 is formed byinstalling a spring 134 into each spring cap 184A (or 184B). The springcaps 184A are then attached to each other by pushing the split pins 86into the pin holes 187 of an adjoining spring cap 184A. Each split pin86 may have multiple flexible arms 191 that bend inward as the split pinpasses into the pin hole 187, and then return to their originalposition, thereby tending to securely hold adjoining spring caps 184Atogether. In an alternative method, the spring caps 184A may first beattached to each other, with a spring 134 then subsequently installedinto each spring cap 184A.

Referring back to FIG. 24B, the ends of most springs 134 are terminatedin an end winding 135 where the wire forming the spring is wound arounditself. When installing a spring into a spring cap, the spring may berotated until the bottom end winding 135 comes to rest against astopping surface, such as a boss 188. In this way, all of the springs134 in a spring core 132 will have the same orientation, as shown forexample in FIG. 33A with all of the top segments 159 of the springs 134parallel to each other, and the mattress 130 may have more consistentfirmness. For springs not having a bottom end winding 135, the bottomend of the spring wire may be bent into a vertical segment and insertedinto spring end socket 185, if used.

Referring now to FIG. 34B, another spring cap 194 may be the same asspring cap 184A but with corner tabs 190 at the top of the spring capinstead of at the bottom, and with the corner tabs 190 provided as partof side frames 195 on opposite sides of the spring cap 194. In addition,the spring cap 194 has modified split pins 196 and pin holes 199extending through bosses 197. A flex tab 198 is pivotally attached toeach boss 197. The flex tab has a collar 201 adapted to close around thesplit pin 196 of an adjoining spring cap 194. A latch hook 202 on thebottom surface of the flex tab 198 engages with a lip 203 on the boss197 when the flex tab 198 is pivoted downward into a closed position.

As shown in FIGS. 34A and 34B, a spring core 132 is formed by installingsprings 134 into spring caps 194. The spring caps 194 are then attachedto each other by inserting the split pins 196 of a first spring cap 194into the pin holes 199 of a second adjoining spring cap 194, with theflex tabs 198 in the up or open position as shown in FIGS. 34A and 34B.The flex tabs 198 are then pivoted into the down or closed position. Thelatch hook 202 snaps into or onto the lip holding the flex tab 198 intothe down position. The collar 201 prevents the split pin 196 fromwithdrawing out of the pin hole 199. Consequently, the spring caps 194cannot be inadvertently separated when the mattress is in use. Todisassemble the mattress 130, the flex tabs 198 are pulled up to theopen position. This allows the split pins to move out of the pin holes199, allowing the spring caps 194 to be separated. The flex tabs 198 maybe attached to the bosses 197 via a so-called living hinge, if thespring caps 194 are molded of plastic material. Of course, solid pinsmay be used in place of split pins.

As shown in FIG. 34B, the split pins 196 are aligned with the pin holes199, i.e., a single center line on a chord 193 of the circular openingof the spring cap passes centrally through both the split pin and thepin hole, on each side of the spring cap. In addition, the chord 193 islocated by a dimension D2 from the centerline 192 of the spring cap,with D2 equal to one quarter of the width D1 of the spring cap. As aresult, when assembled into a spring core 132 as shown in FIGS. 33A, 34Aand 35A, each row of spring assemblies 145 is offset from adjoining rowsby one half of the width of a spring cap.

Referring now to FIGS. 35A, 35B and 35C, another spring cap 204 may bethe same as the spring cap 184B shown in FIG. 33B but further includes acorner frame 207 adjacent to each boss having a split pin 196. On theopposite side, the pin holes 187 pass through split bosses 206. Arelease tab 205 is attached to the outer half of each split boss 206. Aspring core 132 using the spring caps 204 may be assembled by installingsprings 134 into the spring caps 204, and then attaching the spring caps204 to each other by inserting the split pins 196 through the pin holes187. The split bosses 206 may resiliently momentarily move apart toallow the head of the split pin 196 to pass through the pin hole 187.The split pin 196 then cannot be withdrawn without pressing the releasetab 205. This prevents inadvertent separation of the spring caps 204when the mattress is in use. In some cases it may be easier to assemblethe spring caps 204 together before installing the springs.

As shown in FIGS. 36A and 36B, a projection or boss 220 may be providedon the bottom surface of the top pad 136, with the top coil of eachspring around a boss. This can help keep the springs 134 aligned andvertical when the mattress 130 is in use. The boss 220 may be D-shapedto better secure the top end of the spring 134, with top segment 159 ofthe spring 134 against the straight side of the boss.

As shown in FIGS. 37A and 37B, each boss 220 may be positioned within arecess 222 in the bottom surface of top pad 136, to further preventinadvertent displacement of the top end 158 of the spring 134. Thebosses 220, if used, may be of the same material as the top pad 136, orthey may be separate pieces adhered to the top pad.

Referring to FIGS. 38, 39 and 40, because the spring caps are separablefrom each other, and from the springs 134, and because the springs havea conical taper, the springs 134 and the spring caps may be stacked intocompact columns for storage and transport. As shown in FIG. 38, thesprings 134 may be nested into each other to form a compact column ofsprings 232. The spring caps can then be formed into a column of springcaps 234 which is placed over or around the column of springs 232, asshown in FIG. 39. A cup 230 may be placed over the top end of the columnof springs 232. The column of spring caps 234 containing the column ofsprings 232 may be placed into a compact container 236 for transport orstorage. The top pad 136 and side pads 138 may be stored as is, or theymay be rolled, folded or compressed. The mattress 130 accordingly can beshipped and stored in a minimized space. If the spring caps are providedwith an alignment hole 177 as shown in FIG. 32A, a rod may insertedthrough the alignment holes to help keep the spring caps aligned into acolumn.

In the designs described above, with the mattress in use, each spring ofthe spring core is subject to forces individually so that each springmay deflect largely independently of adjoining the springs. The springscan extend and retract individually according to a body contour. Thus,the mattress can evenly and properly support different weights ofdifferent positions of the human body. This can help to keep thesleeper's spine straight and flat and provide more comfortable sleep.When force is exerted on one area, other areas do not move. If onesleeper turns and twists, another sleeper on the mattress will not beaffected. The cone springs having a smaller diameter top coil and alarger diameter bottom coil can make the deformation of the springs morestable when a force acts on the springs in a diagonal direction, so thatleft-right swing or noise generated due to spring friction can bereduced or avoided.

The springs may be arranged in a rectangular shape as shown in FIGS. 26and 28 or a diamond shape as shown in FIG. 29. The diamond shapearrangement of FIG. 29 can effectively improve the spring coverage rate,reduce inter-spring gaps, and enhances the comfort of the mattress.

The present mattress has a simple structure that allows the mattress tobe quickly and easily assembled and dis-assembled. The mattress can becleaned and washed conveniently in a way that not only the cover 140 canbe washed, but the springs 134 can also be cleaned, and the mattress canbe hung under the sun regularly for cleaning and airing.

During transportation and storage, the springs may be stacked one aboveanother to achieve effective packaging, and the soft structures such asthe top and side pads may be compressed, folded or packaged, greatlyreducing storage space requirements. The mattress can be carried in avehicle so that people can enjoy a home-style normal spring mattressoutdoors.

Since the springs have a very long service life, when the cover 140needs to be changed, the springs may be reused. Alternatively, one setof springs can match with many sets of cover materials in use. When themattress is damaged and needs to be disposed or recovered, disposalprocessing is simple and inexpensive due to the detachable structure ofthe mattress.

As shown in FIGS. 41-44, an upper ring-shaped plastic member 302 and alower ring-shaped plastic member 303 are provided, wherein positioningshafts 304 are provided at an upper end face and a lower end face of theupper ring-shaped member, and can be engaged into positioning holes 307formed on the lower ring-shaped member. After the spring 305 isinstalled in the lower ring-shaped plastic member, the upper ring islocked with the lower ring-shaped member by the positioning shafts 304,and then the spring is fixed as shown in FIG. 42. After each set ofplastic members are assembled with the spring, they can be reliablystacked one above another by the positioning shafts and positioningholes as shown in FIG. 43, to provide a stack of conical springs, withD1 greater than or equal to D0+2*n*d, wherein, D1 represents a largerdiameter of the spring, D0 represents a smaller diameter of the spring,n represents the number of coils of the spring, and d represents a wirediameter of the spring. The connection design is as shown in FIG. 44 Thedesign of FIGS. 41-44 may be used in the elastic modules or springassemblies to provide the pads and mattresses discussed above relativeto FIGS. 1-40.

Turning to FIGS. 45 to 49, a spring mattress is divided into a pluralityof independently ascending and descending sections or blocks 306, shownas sections 1-9 in FIG. 48. Each block may either be driven by a motionmechanism 308 to rise and fall independently, or be linked together toperform a controlled movement. This kind of spring mattress may beapplied to a functional bed, a functional sofa, a health care bed, afunctional mattress and the like. It can implement the deformationfunction of the functional bed or the like by virtue of rising andfalling blocks, and achieve purposes such as improving human bodycomfort, stop snoring, providing zero gravity, stretching and pressing.It can also provide simple massage by fast moving the lifting mechanismsvia an electrical control.

Each set comprises at least one spring which may be a conical helicalspring, a cylindrical helical spring, a middle-convex helical spring ora middle-concave helical spring. A sponge structure 310 is attached tothe top of the spring, and a mounting base 312 is provided at the bottomof the spring. Referring to FIGS. 45-47, the base may be pushed by atleast one driving mechanism 308 such as a gas cylinder, a hydrauliccylinder or an electrically-driven cylinder to implement ascending anddescending of the spring set. Alternatively, the ascending anddescending of the spring set may be implemented by the cooperation of amotor and a cam or an eccentric bearing, or by inflation and deflationof an air bag mounted below the base of the spring.

As shown in FIGS. 48 and 49, the sections 1-9 can be distributed eitherregularly or irregularly, and each block may be moved verticallyindependent of the other blocks. As shown in FIG. 51 different blocksmay have varying numbers of spring assemblies and actuators.

In FIGS. 52 and 54, a covering 311 of the whole spring mattress mayemploy a flat and smooth fabric or material or the outer appearance ofthe covering material may be formed as block-shaped protrusions whilethe sponge at the top of the springs is partially recessed properly, sothat the whole mattress looks natural and attractive when the respectivespring sets rise and fall. The fabric may be elastic. The fabric may bepre-formed with pleats 313 configured to fit in between adjacentsections, as shown in FIG. 50. As shown in FIG. 53, a foam or quiltedtop layer 314 may be provided on top of the sections 1-9.

In FIGS. 52-54, gaps may be provided between adjacent blocks so that theproper ascending and descending of the blocks can maximize a contactarea of a human body lying on the mattress and the mattress maintainsthe spine in a horizontal state, thereby achieving an optimal sleepingexperience.

Movement and positioning of the spring blocks may be controlled by anelectrical signal control or APP application control. If the frequencyof rising and falling the blocks is increased, a vibration or impactmassaging effect may be achieved.

As shown in FIG. 54, by controlling each spring block to rise and fallproperly, a zero gravity function of the mattress may be achieved, inwhich a user's legs are lifted to a position higher than the level ofthe heart, and his back and legs form an angle of 126±7 degrees.Additionally, cyclically and repeatedly ascending and descending theblocks enables the mattress to press and extend the human body so as torelax the user and reduce fatigue. Suitable sensors and control systemsmay be used in cooperation. When a sleeper snores during sleep, springblocks near the neck and head are lifted to an inclination angle (about15 degrees) to reduce or stop the snoring. Also as shown in FIG. 54, theactuators may be pivotally attached to the sections 1-9.

A control system may store the rising and falling position of eachspring block in memory so that a number of memory modes may beimplemented. When each of the spring blocks is adjusted in a suitableposition for the first time, it may be quickly adjusted to the mostconformable position from then on.

The structure of the spring sets lifting and falling in blocks may alsobe applied to a medical care bed and a daily-used sofa or couch and mayrealize functionalized and intelligent medical care bed and sofa incooperation with an intelligent control system.

In each of the embodiments described above, the elastic modules orspring assemblies may be attached to each other using only the moduleconnecting structures described, so that no separate lateral orlongitudinal couch or bed frame slats or structural elements orconnecting strips are needed. A perimeter frame around the perimeter ofa spring pad or mattress made up of the elastic modules or springassemblies may optionally be used to provide an improved appearance, andto further hold them in place. No base or tray is needed underneath theelastic modules or spring assemblies to support or hold them in place.

Generally, a spring pad or mattress may be assembled with the endmembers 2 or the spring caps placed edge-to-edge, in contact with eachother, and with no space or gap between them. Each end member or springcap is generally directly attached to four adjacent end members orspring caps, except at the corners and edges where each end member orspring cap is attached to two or three others. The spring pads andmattresses described typically have no rigid or hard element at the top,so as to provide a comfortable support surface for the user.Specifically, the top of the elastic module may include only the outercovering layer made of a soft foam material, which material may have alow thermal conductivity so as to act as an insulator.

As described above the elastic modules and spring assemblies may beassembled without any intermediate elements between them, for examplewithout any walls or dividers between them. The elastic modules andspring assemblies can be provided as substantially simple mechanicalelements, without any electrical components or wiring.

Various changes and substitutions may of course be made withoutdeparting from the spirit and scope of the invention. The presentspecification and examples are considered to be exemplary, and the truescope of the present invention is defined by the appended claims and theequivalent solution thereof. The invention, therefore, should not belimited, except to the following claims, and their equivalents.

1. An elastic module (100), comprising: at least one spring (5); anouter covering layer (1) formed of cushion material and surrounding theat least one spring; a first end member (2) attached to a first end ofthe outer covering layer (1); and at least one of: a module connectingstructure (2 a, 2 b, 3) configured to detachably couple the elasticmodule (100) to another elastic module; and a frame connecting element(2 c) configured to detachably couple the elastic module to a supportframe (7); to assemble a furniture pad or mattress.
 2. The elasticmodule of claim 1 wherein the cushion material comprising polyurethanesponge.
 3. The elastic module of claim 1 having a module connectingstructure comprising one or more of a mechanical link, strap or hook andloop tape.
 4. The elastic module of claim 2 wherein a second end of theouter covering layer (1) has a curvature determined of ergonomics. 5.The elastic module of claim 2 further comprising a second end member (2)attached to a second end of the outer covering layer (1), opposite fromthe first end, and a module connecting structure attached to the secondend member.
 6. The elastic module of claim 5 wherein the moduleconnecting structure comprises a recess (2 a) in the second end member(2) and a protrusion (2 b) on a second end member of a second elasticmodule, with the protrusion configured to engage in the recess (2 a). 7.The elastic module of claim 1 wherein the spring (5) is a spiral springselected from a group consisting of a cylinder spiral spring, conicalspiral spring, middle-portion-convex or concave spiral spring, andspiral spring formed by nesting a left-handed spring and a right-handedspring.
 8. The elastic module of claim 1 wherein the first end membercomprises a material harder than the cushion material.
 9. The elasticmodule of claim 1 wherein the outer covering layer (1) and the at leastone spring (5) are integrally foam-molded within a mold.
 10. The elasticmodule of claim 9 wherein the at least one spring (5) is nested over acore disposed in middle of the mold before molding.
 11. The elasticmodule of claim 1, wherein the outer covering layer (1) is foam-moldedindependently of the at least one spring (5), and wherein a middleportion of the outer covering layer (1) is removed to create a space forinstalling the at least one spring (5) into the outer covering layer.12. The elastic module of claim 1 wherein the outer covering layer (1)partially surrounds the at least one spring (5).
 13. A spring pad (100a, 100 b) formed of a plurality of the elastic modules (100) of any oneof claims 1-12.
 14. The spring pad of claim 13 further including a firstactuator positioned to move a first group of elastic modules vertically,and a second actuator positioned to move a second group of elasticmodules vertically, with the vertical movement of the first groupindependent of the vertical movement of the second group.
 15. The springpad of claim 13 wherein the elastic modules arranged in triangle,square, diamond or hexagon pattern.
 16. The spring pad of claim 13wherein one or more of the elastic modules having an upper ring shapedmember connected to a lower ring shaped member by two or morepositioning shafts.
 17. The spring pad of claim 13 further including acover sheet enclosing or covering the spring pad.
 18. The spring pad ofclaim 17 wherein the cover sheet comprises a smooth fabric material,optionally including pleats inserted between adjacent elastic modules.19. A spring pad (100 a, 100 b), comprising: a plurality of elasticmodules (100) with each elastic module comprising: an outer coveringlayer (1) formed of polyurethane sponge; at least one spring (5)disposed within the outer covering layer (1); an end member (2) attachedto at least one end face of the outer covering layer (1); at least onemounting hole (4) formed on the end member (2); and a separate lockingpiece (3) configured to engage in the at least one mounting hole (4),such that the plurality of the elastic modules (100) can be detachablycoupled together. 20-63. (canceled)